A hybrid coil component in which a magnetic core generally included in a wire-wound type inductor and a core included in a multilayer type inductor are combined with each other. A winding coil may be wound around a magnetic core manufactured in advance and an encapsulant having a stacked structure of a plurality of magnetic sheets may encapsulate the winding coil wound around the magnetic core. In this case, a magnetic flux generated in the winding coil is arranged to be parallel to long axes of magnetic particles contained in the magnetic core and the encapsulant.
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1. A coil component comprising:
a body including a winding coil; and
external electrodes disposed on length-wise opposing external surfaces of the body,
wherein the body includes a magnetic core wound with the winding coil in a thickness direction, and an encapsulant which encapsulates the winding coil,
the magnetic core contains first magnetic particles having shape-related magnetic anisotropy, and the encapsulant contains second magnetic particles having shape-related magnetic anisotropy,
the encapsulant has a stacked structure in which a plurality of magnetic sheets are stacked in a width direction, the plurality of magnetic sheets containing the second magnetic particles,
long axes of the first and second magnetic particles are arranged to be parallel to a direction of a magnetic field formed in the winding coil, and
the second magnetic particles have a short axis perpendicular to the magnetic field of the winding coil.
19. A coil component comprising:
a body including
a winding coil,
a plurality of stacked magnetic cores wound with the winding coil, and
an encapsulant encapsulating the winding coil and the plurality of stacked magnetic cores; and
external electrodes disposed on an external surface of the body,
wherein the body has upper and lower surfaces opposing each other in the thickness direction, first and second end surfaces opposing each other in a length direction, and first and second side surfaces opposing each other in the width direction,
the magnetic cores include first magnetic particles having shape-related magnetic anisotropy,
the encapsulant includes second magnetic particles having shape-related magnetic anisotropy,
the encapsulant has a stacked structure in which a plurality of magnetic sheets containing the second magnetic particles are stacked in the width direction,
long axes of the first and second magnetic particles are arranged to be parallel to a direction of a magnetic field formed in the winding coil,
the second magnetic particles have a first long axis and a second long axis perpendicular to the first long axis, and a short axis parallel to the width direction.
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3. The coil component of
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6. The coil component of
7. The coil component of
8. The coil component of
9. The coil component of
10. The coil component of
11. The coil component of
12. The coil component of
13. The coil component of
14. The coil component of
15. The coil component of
16. The coil component of
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This application claims benefit of priority to Korean Patent Application No. 10-2017-0000439 filed on Jan. 2, 2017 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
The present disclosure relates to a coil component, and more particularly, to a hybrid power inductor in which a molding inductor and a multilayer inductor are coupled to each other.
In general, since particles of a ferrite or metal powder used as a magnetic material in an inductor have a shape close to spherical, when a magnetic field is applied, the magnetic field is equally distributed in all directions rather than in a specific direction. Here, in a case of using a plate-shaped magnetic powder flake of which a long axis and a short axis have different lengths from each other, since a distance of the short axis is shorter than a distance of the long axis, the plate-shaped magnetic powder flake is easily magnetized along its long axis rather than its short axis. In a case of using a magnetic sheet containing the plate-shaped magnetic powder flake having shape-related magnetic anisotropy as described above, an inductor having high permeability may be manufactured.
Korean Patent Laid-Open Publication No. 10-2014-0077346 provides a method of disposing a plate-shaped sheet formed of metal powder in upper and lower cover parts in order to secure high permeability by stacking magnetic sheets containing the plate-shaped powder flake as described above. However, while a plurality of sheets are being stacked, a coil embedded therein may be deformed.
An aspect of the present disclosure may provide a coil component having improved reliability by preventing a coil from being deformed, and having high permeability.
According to an aspect of the present disclosure, a coil component may include: a body including a winding coil; and external electrodes disposed on an external surface of the body. The body may include a magnetic core wound with the winding coil, and an encapsulant encapsulating the winding coil, wherein the magnetic core and the encapsulant may contain first and second magnetic particles having shape-related magnetic anisotropy, respectively. In addition, the encapsulant may have a stacked structure in which a plurality of magnetic sheets containing the second magnetic particle are stacked. Long axes of the first and second magnetic particles may be arranged to be parallel to a direction of a magnetic field formed in the winding coil.
The above and other aspects, features, and advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
Hereinafter, exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings.
Hereinafter, a coil component according to an exemplary embodiment in the present disclosure will be described, but is not necessarily limited thereto.
Referring to
Although a case in which a structure of the first and second external electrodes 21 and 22 has an alphabet C shape is illustrated in
The body 1 may have upper and lower surfaces opposing each other in a thickness (T) direction, first and second end surfaces opposing each other in a length (L) direction, and first and second side surfaces opposing each other in a width (W) direction, and be substantially hexahedron. However, an external shape of the body is not limited at all.
A winding coil 11 may be included in the body 1. Here, a winding method of the winding coil 11 is not limited. For example, the winding coil 11 may be wound by an alpha winding method, an edgewise winding method, or an array winding method.
Structurally, the winding coil 11 may be formed to be wound around a magnetic core 12 and embedded by an encapsulant 13. The magnetic core 12 may contain first magnetic particles 12a having shape-related magnetic anisotropy, and the encapsulant 13 may contain second magnetic particles 13a having shape-related magnetic anisotropy.
The first and second magnetic particles 12a and 13a may be particles formed to have the same composition and the same ingredient ratios as each other, but are not limited thereto. The first and second magnetic particles 12a and 13a may also be particles having different compositions and/or different ingredient ratios from each other.
The first and second magnetic particles 12a and 13a have shape-related magnetic anisotropy, which may mean that long axes of the first and second magnetic particles 12a and 13a may be distinguished from short axes thereof and thus a magnetic flux may be concentrated in a specific direction.
Referring to
Therefore, the first magnetic particle 12a having the plate shape illustrated in
Next,
Referring to
Therefore, it may be appreciated that the first magnetic particle 12a′ having a plate shape illustrated in
Therefore, regardless of a cross-sectional shape of the first magnetic particle 12a′, when the first magnetic particle 12a′ contained in the magnetic core according to the present disclosure is formed so that the maximum length LW thereof extended in the W axis direction is always shorter than the maximum lengths thereof extended in the L and T axis directions, the first magnetic particles 12a′ may be arranged so as to concentrate the magnetic flux of the coil. In a case in which the first magnetic particle 12a′ is disposed so that the long axis of the first magnetic particle 12a′ is not parallel to the W axis, but is parallel to the T axis and/or the L axis, when a flow of the magnetic flux is formed alternately in the T axis direction and the L axis direction, the magnetic flux may be concentrated to the T axis or the L axis.
As illustrated in
Referring to
Similarly, the second magnetic particle 13a contained in the encapsulant 13 may have two or more long axes, and among them, first and second long axes V3 and V4 may be perpendicular to each other. Since the first and second long axes V3 and V4 are perpendicular to each other, the encapsulant 13 may concentrate the magnetic flux generated by the coil 11 throughout regions at the sides of the coil 11 in addition to regions above and below the coil 11. Here, the regions above and below the coil 11 may mean regions of the encapsulant 13 positioned to be higher and lower than the coil 11 in the thickness (T) direction, respectively, and the regions at the sides of the coil 11 may mean regions of the encapsulant 13 positioned to be further extended in the length (L) direction and the width (W) direction than the coil 11.
Further, a length L1 of the magnetic core 12 extended in the length (L) direction may be longer than a length L2 of the winding coil 11 extended in the length (L) direction, such that both end surfaces of the magnetic core 12 may be exposed to external surfaces of the body 1. In this case, since the length L1 of the magnetic core 12 is longer than the length L2 of the winding coil 11, a direction of the magnetic flux generated by the winding coil 11 may be changed in the magnetic core 12. In the coil component 100, since a plurality of long axes are provided in the magnetic core 12, directions of the magnetic flux and the long axis of the magnetic particle e.g. 12a may be controlled to be parallel to each other in an outer portion of the winding coil 11 as well as an inside portion of the winding coil 11. As a result, permeability and inductance of the coil component 100 may be significantly improved.
Next,
In order to more effectively describe a structure of the body 1, the winding coil 11 wound around the magnetic core 12 is omitted in
Referring to
In
Meanwhile, in the first magnetic particle 12a contained in the magnetic core 12, any material may be used without limitation as long as it contains at least one metal to have magnetic properties. For example, a Fe—Ni based permalloy, a Fe—Si—Al based sendust alloy, a Fe—Si based alloy, or the like, may be used. Further, a polymer 12b may be contained around the first magnetic particle 12a. That is, an epoxy resin 12b may be coated on a surface of the first magnetic particle 12a. In this case, the epoxy resin 12b to be coated may be directly disposed on the surface of the first magnetic particle 12a without a separate inorganic insulating layer. A structure in which the epoxy resin 12b is directly coated on the surface of the first magnetic particle 12a may be referred to as a core-shell structure, wherein a core may be formed of one or more of the above-mentioned alloys, and a shell may be formed of the epoxy resin.
Next, the encapsulant 13 encapsulating the winding coil 11 wound around the magnetic core 12 will be described. Referring to
The reason of stacking the magnetic sheets 131, 132, . . . , and 138 in the width (W) direction as the stacking direction in order to configure the encapsulant 13 is to allow the direction of the magnetic flux of the winding coil 11 encapsulated by the encapsulant 13 and the short axis of the second magnetic particle 13a contained in the magnetic sheet 131, 132, . . . , or 138 to be disposed perpendicularly to each other.
Meanwhile, each of the magnetic sheets 131, 132, . . . , or 138 in the encapsulant 13 may have a structure in which a plurality of second magnetic particles 13a are dispersed in a curable resin and adjacent second magnetic particles 13a come into contact with each other.
The number, a size, or the like, of magnetic sheets 131, 132, . . . , and 138 configuring the encapsulant 13 may be suitably selected in consideration of characteristic values to be required, for example, a size of the coil component 100, permeability, or the like. In addition, the curable resin in the magnetic sheet 131, 132, . . . , or 138 may be, for example, an epoxy resin, and the second magnetic particle 13a may be formed of a permalloy.
Next,
Similarly to
Referring to
Meanwhile, since the magnetic core 312, although not specifically illustrated in
The coil component 300 illustrated in
Next,
Referring to
Although the coil component 500 illustrated in
First, in step S701, a magnetic core containing first magnetic particles having shape-related magnetic anisotropy may be formed. In the forming of the magnetic core, the first magnetic particles and a curable resin may be filled together in a mold, compressed at a molding pressure of about 1 to 2 ton/cm2, and then cured, such that the magnetic core may be formed. Alternatively, a bar-shaped magnetic core may be manufactured by stacking, curing and dicing a plurality of magnetic sheets in which the first magnetic particles are dispersed in the curable resin. However, the forming of the magnetic core is not limited thereto.
Next, in step S702, the winding coil may be wound around the magnetic core at a predetermined number of turns. Here, a winding method may be suitably selected, and is not limited. However, in this case, there is a need to allow a direction in which the magnetic flux will be formed in the winding coil not to be arranged to be parallel to a direction of the short axis of the first magnetic particle in the magnetic core. When the magnetic flux and the short axis of the magnetic particle are arranged to be parallel to each other, it is impossible to concentrate the magnetic flux.
In step S703, after the magnetic core including the winding coil wound on the surface thereof is obtained, a plurality of magnetic sheets containing second magnetic particles having shape-related magnetic anisotropy may be stacked, compressed, and cured so as to encapsulate the magnetic core. Here, preferably, a direction in which the magnetic sheets are stacked may be set to be equal to a direction in which the short axis of the first magnetic particle in the magnetic core is arranged. Meanwhile, since the winding coil is in a state in which the winding coil is wound around the magnetic core of which the curing is completed in advance, even in a case of pressurizing the winding coil by stacking and compressing the magnetic sheets, etc, damage or deformation such as distortion of the coil may be significantly decreased.
Next, in step S704, as a general finishing process, lead portions of the winding coil embedded in the body may be exposed to the outside by dicing the body, and in step S705, external electrodes may be formed on surfaces of the lead portions to thereby be electrically connected thereto.
Except for the above-mentioned description, a description of features overlapping those of the coil component according to the exemplary embodiment in the present disclosure described above will be omitted.
As set forth above, according to exemplary embodiments in the present disclosure, the flake having shape-related magnetic anisotropy is applied as the magnetic particle, and the long axis of the flake is disposed to be parallel to the direction of the magnetic field of the coil throughout the entire region including a central portion of the coil and an outer portion of the coil, such that the coil component capable of securing structural reliability by significantly decreasing deformation of the coil while having improved permeability may be provided.
While exemplary embodiments have been shown and described above, it will be apparent to those skilled in the art that modifications and variations could be made without departing from the scope of the present invention as defined by the appended claims.
Seo, Jung Wook, Yoo, Young Seuck, Kwon, Soon Kwang
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Oct 13 2017 | KWON, SOON KWANG | SAMSUNG ELECTRO-MECHANICS CO , LTD | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 044057 | /0866 | |
Oct 13 2017 | YOO, YOUNG SEUCK | SAMSUNG ELECTRO-MECHANICS CO , LTD | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 044057 | /0866 | |
Oct 13 2017 | SEO, JUNG WOOK | SAMSUNG ELECTRO-MECHANICS CO , LTD | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 044057 | /0866 | |
Nov 07 2017 | Samsung Electro-Mechanics Co., Ltd. | (assignment on the face of the patent) | / |
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